Door hinge repair apparatus and method

ABSTRACT

Apparatus for use in repairing, and methods of repairing, a door hinge of a vehicle includes use of a substitute hinge bracket and at least one pin configured to be received through at least one opening of a vehicle frame bracket. A locking portion of the at least one pin and a locking surface that defines an opening in the hinge bracket are configured such that the at least one pin is locked in a fixed position relative to the hinge bracket when assembled. Further, another repair apparatus includes a substitute pin having an interference portion for forming an interference fit with one or more surfaces defining an opening of a factory hinge bracket.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/475,886, filed Jun. 4, 2003, and U.S. Provisional Application No.60/475,860, filed Jun. 4, 2003, both of which are herein incorporated byreference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates generally to door hinges (e.g., vehicledoor hinges). At least in one embodiment, for example, the presentinvention relates to the repair of vehicle door hinges.

There are numerous types of door hinges used on various types ofvehicles. For example, one type of conventional factory door hingeassembly 10 (e.g., for a driver's side of a vehicle) is shown in theprior art diagrams of FIGS. 1-2. For example, such a door hinge is usedon 1999 and various newer vehicles such as a Cadillac Escalade, aCadillac Escalade EXT, a Chevrolet Avalanche, a Chevrolet Silveradopick-up, a Chevrolet Suburban, a Chevrolet Tahoe, a GMC Denali, a GMCSierra pick-up, a GMC Suburban, and a GMC Yukon.

As shown in FIG. 1A, the factory hinge assembly 10 for the vehicle 9includes a factory frame bracket 18 attached to the vehicle frame (e.g.,welded), a factory door bracket 16 attached (e.g., welded) to a driver'sside door 14, and a factory hinge bracket assembly 20 for coupling thefactory vehicle frame bracket 18 to the factory door bracket 16 to mountthe driver's side door 14 relative to the vehicle frame 12. The factoryhinge bracket assembly 20 includes a factory hinge bracket 22 coupled tothe vehicle frame bracket 18 using an upper factory pin 24 and a lowerfactory pin 26.

The factory vehicle frame bracket 18, as shown separately in FIG. 1C,generally includes a body portion 40 for attachment to the vehicle frame12 along with spaced apart extension members 42, 44 extending from thebody portion 40. An upper opening 46 is defined in the upper extensionmember 42 and a lower opening 48 is generally defined in lower extensionmember 44. The upper opening 46 and lower opening 48 are typicallyorthogonal to a factory frame bracket axis 50 along which such openings46, 48 lie.

The factory hinge bracket assembly 20 generally includes a factory hingebracket 22. As shown in FIG. 2, the factory hinge bracket 22 includes abody portion 59 having two spaced apart extension members 52, 54extending therefrom. The extension members 52, 54 are generallyconfigured such that the factory hinge bracket 22 fits within a spacedefined by the extension members 42, 44 of factory vehicle frame bracket18.

Although not shown in FIG. 2, factory hinge bracket 22 further includesopenings defined in each of extension members 52, 54. When the factoryhinge bracket 22 and the vehicle frame bracket 18 are assembled, theopenings defined in each of extensions members 52, 54 and the openings46, 48 defined in extension members 42, 44 of the vehicle frame bracket18 are generally aligned along axis 50 of the vehicle frame bracket 18and lie orthogonal to the axis 50.

The factory hinge bracket 22 is coupled to the frame bracket 18 usingthe upper factory pin 24 and lower factory pin 26. As best shown in FIG.2, the upper factory pin 24 is inserted through the upper opening 46defined in extension member 42 of the factory vehicle frame bracket 18and also through the opening (not shown) in extension member 52 offactory hinge bracket 22. Prior to insertion of the upper factory pin24, a bushing (not shown) is also inserted into opening 46 of thefactory vehicle frame bracket 18. A peened end 25 of the upper factorypin 24, along with engagement element 23 of upper factory pin 24,provide for coupling of the extension member 52 of the hinge bracket 22to the upper extension member 42 of the factory vehicle frame bracket18, and further provide a pin end portion 29 over which factory doorbracket 16 may be placed.

Likewise, after insertion of a bushing (not shown) within lower opening48 of lower extension member 44 of factory vehicle frame bracket 18,lower factory pin 26 is inserted through the opening defined in thelower extension member 54 of the factory hinge bracket 22 and throughlower opening 48 in lower extension member 44 of the vehicle framebracket 18. Peened end 27 of lower factory pin 26, as well as engagementelement 31 of lower factory pin 26, hold a lower factory pin 26 inposition for coupling the factory hinge bracket 22 to the factoryvehicle frame bracket 18, and further provide a pin end portion 37 overwhich the factory door bracket 16 may be placed.

The factory door bracket 16, as shown in FIG. 1B, typically includes abracket body portion 28 with spaced apart extension members 30, 32extending from body portion 28. Generally, the body portion 28 isattached to the door 14 of the vehicle 9, such as, for example, bywelding.

An upper opening 34 is defined in extension member 30 and a loweropening 36 is defined in extension member 32. Generally, the upperopening 34 and the lower opening 36 are spaced a distance apart alongfactory door bracket axis 41. Generally, such upper and lower openings34, 36 lie orthogonal to axis 41.

With the door bracket 16 attached to the door 14, the door 14 may behung via the upper and lower openings 34, 36 on pin end portions 29, 37of the factory binge bracket assembly 20. After the door 14 ispositioned relative to the vehicle frame 12 via the factory hinge 10,the door 14 may further be adjusted.

For example, as shown in FIG. 1B, a factory adjustment slot 43 may beprovided in a tab of the factory door bracket 16, and a bolt opening 49may be provided in the body portion 50 of the factory hinge bracket 22.A bolt or any other fastening or coupling mechanism 51, as shown in FIG.1A, may be used to adjust the factory door bracket 16 vertically withrespect to factory hinge bracket 22 by insertion of the bolt 51 throughthe bolt opening 49 in the hinge bracket 22 and through factoryadjustment slot 43 of factory door bracket 16. With the door in anadjusted position, the bolt (or any other suitable hardware) may be usedto lock the factory door bracket 16 into a position relative to thefactory hinge bracket 22.

In many circumstances, the factory door bracket 16 is welded to door 14and the vehicle frame bracket 18 is welded to the vehicle frame 12. Assuch, if a factory hinge 10 becomes defective, a standard method ofrepair would include removing the defective hinge assembly 10 andwelding on new components. Further, the new components would have to bepainted, as typically they are not coated from the factory. In somecircumstances, both hinges of the door may need to be repaired. Such aremoval and replacement process is very costly, both in terms of theparts needed to complete the repair, as well as labor costs.

SUMMARY OF THE INVENTION

The present invention provides apparatus and methods which reduce thecost associated with defective vehicle door hinge removal andreplacement, such as repair of a door hinge described above in theBackground of the Invention.

An apparatus for use in repairing a door hinge of a vehicle according tothe present invention is described herein. The door hinge includes atleast a vehicle frame bracket attached to a portion of a vehicle frameof the vehicle. The vehicle frame bracket includes at least one openingdefined therein.

The apparatus for use in the repair includes at least one pin configuredto be received through the at least one opening of the vehicle framebracket. The at least one pin includes a locking portion. The apparatusfurther includes a hinge bracket, wherein the hinge bracket includes atleast one opening corresponding to the at least one opening of thevehicle frame bracket. The at least one opening of the hinge bracket isdefined by a locking surface configured as a function of the lockingportion of the at least one pin such that the at least one pin is lockedin a fixed position relative to the hinge bracket when at least a partof the locking portion of the pin is positioned in at least part of theat least one opening of the hinge bracket.

In one embodiment of the apparatus, the locking portion of the pinincludes a threaded region, and at least a portion of the lockingsurface of the hinge bracket is threaded for receiving the threadedregion of the pin.

In another embodiment of the apparatus, the locking portion of the pinincludes one or more flat surfaces, and the locking surface of the hingebracket includes at least one flat surface configured to correspond tothe one or more flat surfaces of the locking portion of the pin.

In yet another embodiment of the apparatus, the at least one pin furtherincludes a threaded end portion configured to be inserted through the atleast one opening defined in the vehicle frame bracket and the at leastone opening defined in the hinge bracket. Further, the apparatusincludes a nut for coupling to the threaded end portion.

In another embodiment of the apparatus, the at least one pin includes anelongated pin end portion extending along a pin axis at an end oppositethe threaded end portion of the at least one pin. The at least one pinincludes an engagement element (e.g., the engagement element configuredwith one or more grasping surfaces such that a tool corresponding tosuch grasping surfaces can be used to hold the engagement element)extending orthogonal to the pin axis at a position between the threadedend portion and the pin end portion to maintain the pin end portion at aposition to receive a door bracket of the vehicle when a nut is coupledto the threaded end portion.

In another embodiment, the apparatus further includes a bushingconfigured for insertion through the at least one opening defined in thevehicle frame bracket, wherein an opening is defined by the bushing, andfurther wherein the at least one pin is configured for insertion throughthe opening defined by the bushing.

In yet another embodiment, the vehicle frame bracket includes a firstand second opening aligned along and lying orthogonal to a frame bracketaxis. In this embodiment, a first pin is configured to be receivedthrough the first opening of the vehicle frame bracket and a second pinis configured to be received through the second opening of the vehicleframe bracket. Each of the first and second pins includes a lockingportion (e.g., at least one pin includes a material that has a hardnessthat is greater than about 80 Rockwell B Hardness (HRB)) configured toprovide a locking function with locking surfaces of first and secondopenings of the hinge bracket.

A method for repairing a door hinge according to the present inventionis also provided. The door hinge being repaired includes at least avehicle frame bracket attached to a portion of a vehicle frame and ahinge bracket. The vehicle frame bracket includes a first and secondopening aligned along and lying orthogonal to a frame bracket axis. Thehinge bracket includes a first and second opening aligned along andlying orthogonal to the frame bracket axis. The vehicle frame bracketand the hinge bracket are coupled using a first pin positioned in thefirst opening of the vehicle frame bracket and the first opening of thehinge bracket and using a second pin positioned in the second opening ofthe vehicle frame bracket and the second opening of the hinge bracket.

The repair method includes removing the first and second pins to releasethe hinge bracket from the vehicle frame bracket and providing a firstsubstitute pin configured to be received through the first opening ofthe vehicle frame bracket and a second substitute pin configured to bereceived through the second opening of the vehicle frame bracket (e.g.,each of the first and second substitute pins comprise a lockingportion). The method further includes providing a substitute hingebracket that includes a first and second opening aligned orthogonal on asubstitute hinge bracket axis. Each of the first and second openings ofthe substitute hinge bracket are defined by a locking surface configuredas a function of the locking portion of the respective first and secondsubstitute pins such that the first substitute pin is locked in a fixedposition relative to the substitute hinge bracket when at least a partof the locking portion of the first substitute pin is positioned in thefirst opening of the substitute hinge bracket and such that the secondsubstitute pin is locked in a fixed position relative to the substitutehinge bracket when at least a part of the locking portion of the secondsubstitute pin is positioned in the second opening of the substitutehinge bracket. To implement the repair, the substitute hinge bracketaxis and the vehicle frame bracket axis are aligned and the vehicleframe bracket and the substitute hinge bracket are coupled using thefirst and second substitute pins.

In one embodiment of the method, the locking portion of each of thefirst and second substitute pins include a threaded region, and furtherwherein each locking surface defining the first and second openings ofthe substitute hinge bracket is threaded for receiving the threadedregion of the respective first and second substitute pins. In analternate embodiment, the locking portion of each of the first andsecond substitute pins includes one or more flat surfaces, and furtherwherein each locking surface defining the first and second openings ofthe substitute hinge bracket comprises at least one flat surfaceconfigured to correspond to the flat surface of the locking portion ofthe respective first and second substitute pins.

In another embodiment, each of the first and second substitute pinsincludes a threaded end portion. The method then further includescoupling a first nut on the threaded end portion of the first substitutepin after the first substitute pin is inserted through the first openingof the vehicle frame bracket and the first opening of the substitutehinge bracket and coupling a second nut on the threaded end portion ofthe second substitute pin after the second substitute pin is insertedthrough the second opening of the vehicle frame bracket and the secondopening of the substitute hinge bracket.

In yet another embodiment, each of the first substitute pin and secondsubstitute pin includes an elongated pin end portion extending along apin axis at an end opposite the threaded end portion of the firstsubstitute pin, and further wherein each of the first substitute pin andsecond substitute pin includes an engagement element extendingorthogonal to the pin axis at a position between the threaded endportion and the pin end portion to maintain the pin end portion at aposition to receive a door bracket. Further, the door bracket includes afirst opening to be positioned on the pin end portion of the firstsubstitute pin and a second opening to be positioned on the pin endportion of the second substitute pin after the vehicle frame bracket andthe substitute hinge bracket are coupled using the first and secondsubstitute pins. Further, the engagement element of each of the firstsubstitute pin and second substitute pin may be configured with one ormore grasping surfaces such that coupling the vehicle frame bracket andthe substitute hinge bracket using the first and second substitute pinscan be assisted by holding and/or turning at least one of the firstsubstitute pin and second substitute pin using a tool corresponding tosuch grasping surfaces.

In yet another embodiment of the method, removing the first and secondpins to release the hinge bracket from the vehicle frame bracketincludes removing ends of the first and second pins holding the firstand second pins in the openings of the hinge bracket and vehicle framebracket and pushing the first and second pins out of the openings of thehinge bracket and vehicle frame bracket using a punch tool.

In one embodiment, the punch tool includes a body portion and first andsecond spaced apart portions extending from the body portion to define abracket receiving region therebetween configured to receive a portion ofthe vehicle frame bracket and the hinge bracket when the tool is used toremove one of the first and second pins. Further, one of the first andsecond spaced apart portions defines a pin receiving region configuredto receive one of the first and second pins when the tool is used toremove the pin and the other of the first and second spaced apartportions defines a threaded opening configured to receive a threadedpunch screw operable to engage the pin when the tool is being used toremove the pin.

Another apparatus for use in repairing a door hinge of a vehicle is alsodescribed herein. The door hinge being repaired includes at least avehicle frame bracket attached to a portion of a vehicle frame of thevehicle and a hinge bracket (e.g., a factory hinge bracket). The vehicleframe bracket includes at least one opening defined therein and thehinge bracket includes at least one opening corresponding to the atleast one opening of the vehicle frame bracket. The apparatus for use inthe repair includes at least one pin configured to be received throughthe at least one opening of the vehicle frame bracket. The at least onepin includes an interference portion to form an interference fit withone or more surfaces defining the at least one opening of the hingebracket (e.g., factory hinge bracket) when at least a part of theinterference portion of the pin is positioned in at least part of the atleast one opening of the hinge bracket. The pin further includes athreaded end portion configured to be inserted through the at least oneopening defined in the vehicle frame bracket and the at least oneopening defined in the hinge bracket for coupling to a nut. Further, thepin includes an elongated pin end portion extending along a pin axis atan end opposite the threaded end portion of the at least one pin. Anengagement element extends orthogonal to the pin axis at a positionbetween the threaded end portion and the pin end portion to maintain thepin end portion at a position to receive a door bracket of the vehiclewhen the nut is coupled to the threaded end portion. The engagementelement is configured with one or more grasping surfaces such that atool corresponding to such grasping surfaces can be used to hold and/orturn the engagement element.

In one embodiment of the apparatus, the vehicle frame bracket includes afirst and second opening aligned along and lying orthogonal to a framebracket axis. The hinge bracket includes a first and second openingaligned along and lying orthogonal to a hinge bracket axis. The hingebracket axis and the frame bracket axis coincide and the first andsecond openings of the hinge bracket axis lie adjacent to the first andsecond openings of the vehicle frame bracket, respectively, when thehinge bracket is assembled with the vehicle frame bracket. In thisembodiment, a first pin is configured to be received through the firstopening of the vehicle frame bracket and a second pin is configured tobe received through the second opening of the vehicle frame bracket. Thefirst pin includes an interference portion to form an interference fitwith one or more surfaces defining the first opening of the hingebracket when at least a part of the interference portion of the firstpin is positioned in at least part of the first opening of the hingebracket and the second pin includes an interference portion to form aninterference fit with one or more surfaces defining the second openingof the hinge bracket when at least a part of the interference portion ofthe second pin is positioned in at least part of the second opening ofthe hinge bracket.

In another embodiment of the apparatus, the interference portion isconfigured such that substantially an entire inner surface defining theat least one opening of the hinge bracket is in contact with theinterference portion of the at least one pin when at least a part of theinterference portion of the pin is positioned in the at least oneopening of the hinge bracket.

A method for repairing a door hinge (e.g., without using a substitutehinge bracket) is also described. The door hinge includes at least avehicle frame bracket attached to a portion of a vehicle frame and ahinge bracket. The vehicle frame bracket includes a first and secondopening aligned along and lying orthogonal to a frame bracket axis andthe hinge bracket includes a first and second opening aligned along andlying orthogonal to the frame bracket axis. The vehicle frame bracketand the hinge bracket are coupled using a first pin positioned in thefirst opening of the vehicle frame bracket and the first opening of thehinge bracket and using a second pin positioned in the second opening ofthe vehicle frame bracket and the second opening of the hinge bracket.The repair method includes removing the first and second pins (e.g.,using the punch tool) to release the hinge bracket from the vehicleframe bracket and providing a first substitute pin configured to bereceived through the first opening of the vehicle frame bracket and asecond substitute pin configured to be received through the secondopening of the vehicle frame bracket.

At least one of the first and second substitute pins includes aninterference portion to form an interference fit with one or moresurfaces defining the opening of the hinge bracket in which the at leastone substitute pin is to be received and a threaded end portionconfigured to be inserted through the opening defined in the vehicleframe bracket and the opening defined in the hinge bracket for couplingto a nut. An elongated pin end portion extends along a pin axis at anend opposite the threaded end portion of the at least one pin. The atleast one substitute pin further includes an engagement elementextending orthogonal to the pin axis at a position between the threadedend portion and the pin end portion to maintain the pin end portion at aposition to receive a door bracket of the vehicle when the nut iscoupled to the threaded end portion. The engagement element isconfigured with one or more grasping surfaces such that a toolcorresponding to such grasping surfaces can be used to hold and/or turnthe engagement element. The repair method further includes aligning thehinge bracket and the vehicle frame bracket and coupling the vehicleframe bracket and the hinge bracket using the first and secondsubstitute pins, wherein coupling the vehicle frame bracket and thehinge bracket includes using the tool corresponding to the graspingsurfaces to hold and/or turn at least one of the first and secondsubstitute pins.

In one embodiment of the method, the interference portion is configuredsuch that substantially an entire inner surface defining the opening ofthe hinge bracket is in contact with the interference portion of thesubstitute pin when at least a part of the interference portion of thesubstitute pin is positioned in the opening of the hinge bracket.

The above summary of the present invention is not intended to describeeach embodiment or every implementation of the present invention. Forexample, the apparatus and the punch tool may be provided as a kit,portions of the apparatus may be provided and/or used separately or incombination, the punch tool may be provided separately, etc. Advantages,together with a more complete understanding of the invention, willbecome apparent and appreciated by referring to the following detaileddescription and claims taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a factory door hinge mounting a door toa vehicle frame.

FIG. 1B is a perspective view of a factory door bracket of the factoryhinge as shown in FIG. 1A.

FIG. 1C is a perspective view of a factory vehicle frame bracket of thefactory hinge as shown in FIG. 1A.

FIG. 2 is a diagrammatic illustrative view of a factory hinge bracketassembly coupled to a factory vehicle frame bracket such as shown inFIG. 1A.

FIG. 3 is an exploded view of a hinge pin and bracket apparatusaccording to the present invention shown in relation to a factoryvehicle frame bracket for a driver's side of a vehicle.

FIG. 4 shows an assembled view of the components shown in FIG. 3according to the present invention.

FIG. 5 shows an exploded view of a hinge pin and bracket apparatus for apassenger side of a vehicle according to the present invention inrelation to a factory vehicle frame bracket for the passenger's side ofthe vehicle.

FIG. 6 is an exploded view of the hinge pin and bracket apparatus shownin FIG. 3 apart from the vehicle frame bracket.

FIG. 7 is a cross-section taken at line 7-7 of FIG. 4 showing anassembled hinge pin and bracket apparatus according to the presentinvention in relation to a vehicle frame bracket.

FIG. 8A is a perspective view of one embodiment of an upper pin such asgenerally shown in FIGS. 3-4 and 6-7.

FIG. 8B is a side view of the upper pin shown in FIG. 8A.

FIG. 8C is a top view of the upper pin shown in FIGS. 8A-8B.

FIG. 9A is a perspective view of one embodiment of a lower pin such asshown generally in FIGS. 3-4 and FIGS. 6-7.

FIG. 9B is a side view of the lower pin shown in FIG. 9A.

FIG. 9C is a top view of the lower pin shown in FIGS. 9A-9B.

FIG. 10 is a perspective view of one embodiment of a hinge bracket asshown generally in FIGS. 3-4 and FIGS. 6-7.

FIGS. 11A-11C show perspective views of an alternate embodiment of anupper pin, a lower pin, and a hinge bracket, respectively, that may beused in an alternate configuration of a hinge pin and bracket apparatusaccording to the present invention.

FIG. 12 is a perspective view of a punch-out block tool that may be usedaccording to the present invention to remove factory pins such as thoseshown in FIGS. 1A and 2.

FIGS. 13A-13C show an end view, a plan view, and a side view of thepunch-out block tool shown in FIG. 12; FIG. 13C further shows thethreaded screw and the punch-out block tool thereof being positionedrelative to a factory hinge such as that shown in FIG. 1A.

FIG. 14 shows an exploded view of a hinge pin apparatus for a door hingerepair of a passenger side of a vehicle according to the presentinvention in relation to a factory vehicle frame bracket and a factoryhinge bracket for the passenger's side of the vehicle.

FIG. 15A is a side view of an upper pin shown in FIG. 14.

FIG. 15B is a top view of the upper pin shown in FIG. 15A.

FIG. 16A is a side view of a lower pin shown in FIG. 14.

FIG. 16B is a top view of the lower pin shown in FIG. 16A.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Apparatus, kits, systems, and methods shall first generally be describedwith reference to FIGS. 3-10, wherein an illustrative and exemplary doorhinge pin and bracket apparatus 60 according to the present invention isshown. For example, the hinge pin and bracket apparatus 60 may be usedto repair a factory hinge (e.g., a hinge provided on a new vehicle) suchas factory hinge 10 shown generally in FIGS. 1-2. Thereafter, anotherillustrative and alternate embodiment of a hinge pin and bracketapparatus shall be described with reference to FIGS. 11A-11C. Further, apunch-out block tool for use in repair of a factory hinge such as thatshown in FIGS. 1-2 shall be described generally with reference to FIGS.12-13. Yet further, another illustrative and alternate embodiment of ahinge pin apparatus shall be described with reference to FIGS. 14-16which uses the factory hinge bracket for the repair as opposed to use ofa substitute hinge bracket.

Various embodiments, according to the present invention, may beimplemented as described herein. It is noted that various combinationsof elements may provide the functionality described herein and thatvarious structure and process steps described herein may be includedand/or may be optional according to the present invention. It will berecognized that the drawings provided herein are for illustrativepurposes only and are not necessarily shown to scale.

Further, one or more features of each of the embodiments may be modifiedand still perform the same functionality or additional functionalitywithout departing from the scope of the present invention. For example,the size of threads for various portions of the pins described hereinmay vary, the diameter of the pins at various regions thereof may vary(e.g., for example, the threaded portions may be provided at a differentdiameter than one or more other portions of the pin to provide largershoulders or engagement surfaces enhancing contact areas with othercomponents), and various shapes and sizes of bracket or pin componentsmay be used (e.g., hinge brackets may have curved corners versusstraight corners, various tabs or openings may be provided in one ormore brackets, the shape and/or configuration of the pins and bracketsmay vary to accommodate coupling of one or more components describedherein, etc.).

One or more components as described herein may be provided as a repairkit for the repair of a factory hinge such as that shown and describedwith reference to FIGS. 1-2. For example, the hinge pin and bracketapparatus 60, as shown in FIG. 3, includes components (e.g., upper hingepin components 64 and lower hinge pin components 66, as well assubstitute hinge bracket 62) for repair of a driver's side door hinge10. One skilled in the art will recognize that one or more of such kitelements may be optional. For example, washers (e.g., lock washers)shown as part of upper hinge pin components 64 and lower hinge pincomponents 66 may optionally be used according to the present invention.Further, a kit may be provided with any combination of the repaircomponents described herein.

Upper hinge pin components 64, at least in one embodiment, include upperpin 70, upper bushing 72, upper washer 73, and upper lock nut 74.Likewise, lower hinge pin components 66 include lower pin 80, lowerbushing 82, lower washer 84, and lower lock nut 86. Such components 64,66 are shown unassembled in the exploded view of FIG. 3 along with afactory vehicle frame bracket 18, as well as separately in the explodedview of FIG. 6. Such components 64, 66 are shown assembled incombination with hinge bracket 62 in relation to vehicle frame bracket18 in the assembled view of FIG. 4 and the cross-section view of FIG. 7taken at line 7-7 of FIG. 4.

FIG. 5 shows an exploded view of a hinge pin and bracket apparatus 100for a passenger side hinge repair in relation to a passenger sidevehicle frame bracket 19. The passenger side hinge pin and bracketapparatus 100 includes passenger side hinge bracket 102, upper hinge pincomponents 104, and lower hinge pin components 106. As one skilled inthe art will recognize, the passenger side components are merely amirror image of the driver's side components and as such shall not bedescribed in any further detail herein.

FIGS. 8A-8C show a perspective view, a side view, and a top view of oneembodiment of an upper hinge pin 70 shown generally in FIGS. 3-4 and 6-7according to the present invention. The upper hinge pin 70 includes anelongated body portion 71 extending from a threaded end portion 132 to apin end portion 130 along axis 129.

A locking surface 134 lies along the axis 129 between the threaded endportion 132 and the pin end portion 130. The locking surface 134, asshall be described further herein, is shown as a threaded portion inFIGS. 8A-8B.

However, according to the present invention, any locking surface thatprovides for a locking functionality between the upper pin 70 and thehinge bracket 62 when the pin 70 is positioned within upper opening 97of hinge bracket 62, as shall be described further herein with referenceto FIG. 10, may be used. Locking functionality refers to anyconfiguration that does not allow the pin to move relative to the hingebracket 62 when assembled therewith. For example, other locking surfacesshall be described herein with reference to FIGS. 11A-11C.

Also lying along axis 129 between threaded end portion 132 and pin endportion 130 is smooth surface 136. As will be recognized upon reading ofthe description relating to the assembled hinge pin and bracketapparatus 60, smooth surface 136 generally corresponds to an opening ofbushing 72 through which the upper hinge pin 70 is inserted (e.g., thesmooth surface 136 is generally adjacent an inner surface of bushing 72when assembled).

As shown in FIG. 8A, the smooth surface 136 lies between the lockingsurface 134 and pin end portion 130. At the interface between smoothsurface 136 and locking surface 134 is a shoulder 137. Although shown asa very small shoulder at the interface between smooth surface 136 andlocking surface 134, one will recognize that by changing the diameter ofthe smooth surface 136 or the locking surface 134, that such shoulder137 may be enlarged and provide even a greater contact area for use incoupling with other components of the hinge pin and bracket apparatus60, as shall be described further herein.

The upper hinge pin 70 further includes an engagement element 138 lyingalong axis 129 and which extends further radially from axis 129 thanother portions of the elongated pin body portion 71. As such, a lowersurface 141 is provided for contact with other components so as tomaintain pin end portion 130 available to receive a factory doorbracket, such as factory door bracket 16 shown and described withreference to FIGS. 1A-1B. The pin end portion 130 further includes atapered end 131 for ease in receiving the factory door bracket 16 as theopening 34 of the factory door bracket 16 is placed over the tapered end131.

The engagement element 138 further includes one or more grasp surfaces140. The one or more grasp surfaces 140 are configured in acorresponding manner to one or more tools capable of grasping andholding (and/or turning) the upper pin 70 as the hinge pin and bracketapparatus 60 is being assembled in relation to hinge bracket 62 and/orvehicle frame bracket 18, as shall be further described herein. Oneskilled in the art will recognize that such grasping surfaces 140 may beflat surfaces that can be grasped (i.e., to hold the pin 70) by awrench, a socket, or any other tool capable of grasping and holding(and/or turning) the upper hinge pin 70 during assembly. For example,the grasp surfaces 140 may include six flat surfaces in the form ofsubstantially a hexagon such that a socket wrench may be used to holdthe upper hinge pin 70.

One skilled in the art will recognize that the diameter of the variousregions of upper hinge pin 70 will vary depending upon the hinge bracket62 as well as openings of other components to which it is coupled.Further, the size of the threads of threaded end portion 132 and lockingsurface 134 may be the same or may be different, as shown in FIGS.8A-8B.

FIGS. 9A-9C show a perspective view, a side view, and a top view of oneembodiment of a lower hinge pin 80 shown generally in FIGS. 3-4 and 6-7according to the present invention. The lower hinge pin 80 includes anelongated body portion 147 extending from a threaded end portion 152 toa pin end portion 150 along axis 149.

A locking surface 156 lies along the axis 149 between the threaded endportion 152 and the pin end portion 150. The locking surface 156, asshall be described further herein, is shown as a threaded portion inFIGS. 9A-9B. However, as described above with respect to the upper hingepin 70, any locking surface that provides for a locking functionalitybetween the lower hinge pin 80 and a lower opening 98 of hinge bracket62, as shall be described further herein with reference to FIG. 10, maybe used.

Also lying along axis 149 between threaded end portion 152 and pin endportion 150 is smooth surface 154. As will be recognized upon reading ofthe description relating to the assembled hinge pin and bracketapparatus 60, smooth surface 154 generally corresponds to an opening ofbushing 82 through which the lower hinge pin 80 is inserted (e.g., thesmooth surface 154 is generally adjacent an inner surface of bushing 82when assembled).

As shown in FIG. 9A, the smooth surface 156 lies between the threadedend portion 152 and locking surface 156. At the interface betweenthreaded end portion 152 and smooth surface 154 is a shoulder 157.Although shown as a very small shoulder at the interface betweenthreaded end portion 152 and smooth surface 154, one will recognize thatby changing the diameter of the smooth surface 154 or the threaded endportion 152, that such shoulder 157 may be enlarged and provide even agreater contact area for use in coupling with other components of thehinge pin and bracket apparatus 60, as shall be described furtherherein.

The lower hinge pin 80 further includes an engagement element 158 lyingalong axis 149 and which extends further from axis 149 than otherportions of the elongated pin body portion 147. As such, a lower surface143 is provided for contact with other components so as to maintain pinend portion 150 available to receive a factory door bracket, such asfactory door bracket 16 shown and described with reference to FIGS.1A-1B. The pin end portion 150 further includes a tapered end 151 forease in receiving the factory door bracket 16 as the opening 36 of thefactory door bracket 16 is placed over the tapered end 151.

The engagement element 158 further includes one or more grasp surfaces160. The one or more grasp surfaces 160 are configured in acorresponding manner to one or more tools capable of grasping andholding (and/or turning) the lower pin 80 as the hinge pin and bracketapparatus 60 is being assembled in relation to hinge bracket 62 and/orvehicle frame bracket 18, as shall be further described herein. Oneskilled in the art will recognize that such grasping surfaces 160 may bethe same or different than those described with reference to upper hingepin 70.

One skilled in the art will recognize that the diameter of the variousregions of lower hinge pin 80 will vary depending upon the hinge bracket62 as well as openings of other components to which it is coupled.Further, the size of the threads of threaded end portion 152 and lockingsurface 156 may be the same or may be different, as shown in FIG. 9A-9B.

A perspective view of one embodiment of hinge bracket 62 shown generallyin FIGS. 3-4 and 6-7 according to the present invention is shown in FIG.10. The hinge bracket 62 is, at least in one embodiment, of the sameshape and size as factory hinge bracket 22 for which it is to replace.However, instead of having openings like those of the factory bingebracket 22 through which factory pins are inserted, the hinge bracket 62to be substituted for the factory hinge bracket 22 includes openings 97,98 defined therein by locking surfaces 160, 164, respectively, whichcorrespond to locking surfaces 134, 156 of upper hinge pin 70 and lowerhinge pin 80, respectively.

Preferably, hinge bracket 62 is produced by stamping of a planar sheetof metal and thereafter bending the stamped component to a configurationfor use in repair of a factory hinge 10, such as that described withreference to FIGS. 1-2. The locking surfaces 160, 164 provided in hingebracket 62 may either be produced during the stamping process or by oneor more later processes (e.g., a thread cutting process).

As shown in FIG. 10, the hinge bracket 62 includes a bracket body 90with two spaced apart extension members 92, 94 extending therefrom. Atleast in one embodiment, such extension members 92, 94 each have atleast a portion which are substantially parallel to one another. Anopening 97 is defined in the upper extension member 92 and an opening 98is defined in the lower extension member 94. Such openings 97, 98 liesubstantially orthogonal to hinge bracket axis 93. Generally, thedistance between upper extension member 92 and lower extension member 94is such that the hinge bracket 62 may be inserted between extensionmembers 42, 44 of vehicle frame bracket 18, such as described withreference to FIGS. 1-2. As shown in FIG. 10, the locking surfaces 160,164 include threaded surfaces corresponding to the threaded lockingsurface regions 134, 156 of upper hinge pin 70 and lower hinge pin 80,respectively.

The substitute hinge bracket 62 (e.g., substitute for a factory hingebracket) also includes bolt opening 91 in substantially the samelocation as the factory hinge bracket (e.g., hinge bracket 22) which itis to replace. As such, hinge bracket 62, at least in one embodiment,includes substantially all the features present in the factory hingewhich it is to replace.

With provision of hinge pin and bracket apparatus 60, a method ofrepairing a factory hinge (e.g., a factory hinge 10 shown and describedwith reference to FIGS. 1-2) shall be described with reference to FIGS.1-10. Although such a repair method is described herein with referenceto factory hinge 10, shown and described with reference to FIGS. 1-2,one skilled in the art will recognize that various types of hinges maybe repaired in the same or a similar manner.

To begin the repair process, the driver's side door 14 is removed fromthe vehicle 9. Generally, removal of door 14 is described in a factoryprovided manual and may include one or more various steps. As is clearfrom FIG. 1, the removal of driver's side door 14 would include at leastremoval of factory bolt 51 which couples the factory hinge bracket 22 tothe factory door bracket 16. Likewise, the driver's side door 14 mustthen be lifted off of upper factory pin 24 and lower factory pin 26. Thepeened ends 25, 27 of upper factory pin 24 and lower factory pin 26,respectively, must then be removed. For example, any sort of removalmethod may be used, such as, for example, grinding off of the peenedends 25, 27.

Thereafter, the upper factory pin 24 and the lower factory pin 26 areremoved. For example, such factory pins 24, 26 may be removed using ahole punch. However, preferably, any method suitable to remove the upperand lower pins 24, 26 without bending the vehicle frame bracket 18 canbe utilized.

In one embodiment, the punch-out block tool 302, as shown in FIGS.12-13, may be used to remove the upper and lower factory pins 24, 26.The punch-out block tool 302 includes a body portion 304 having spacedapart extension portions 306, 308 extending therefrom (e.g., extensionsgenerally parallel to one another and/or orthogonal to a linear bodyportion). The space between the extension portions 306, 308 provide abracket receiving opening 314 sized to receive at least a portion ofvehicle frame bracket 18 and the factory hinge bracket 22, as shown inthe side view of FIG. 13C.

The extension portion 306 further defines a pin receiving opening 312sized to receive one of upper factory pin 24 or lower factory pin 26therein. As shown in the end view of FIG. 13A, the plan view of FIG.13B, and the side view of FIG. 13C, the extension portion 308 defines athreaded screw opening 320 sized to receive a threaded screw 303.

In one illustrative example, removal of upper factory pin 24 using thepunch-out block tool 302 will be described. One will recognize that theremoval of the lower factory pin 26 can be accomplished in a similarmanner.

To remove the upper factory pin 24, the factory hinge bracket 22 isrepositioned to allow fitting of the punch-out block tool 302 forremoval of the upper factory pin 24, as shown in FIG. 13C. For example,the upper factory pin 24 is received in receiving opening 312 of thepunch-out block tool 302. Further, upper extension member 42 of vehicleframe bracket 18, as well as extension member 52 of factory hingebracket 22, are received within bracket receiving opening 314 of thepunch-out block tool 302.

With such components in the defined openings 312, 314, the threadedscrew 303 may be used to remove the upper factory pin 24. The threadedscrew 303 includes a threaded portion 332 sized for mating with threadedscrew opening 320, a head configured to be grasped by a correspondingtool (e.g., a hex socket), and an engagement point 333 opposite the head330. The engagement point 333 may include any surface configured toengage the ground off end of upper factory pin 24.

To remove the upper factory pin 24, the threaded screw 303 is turnedthrough threaded opening 320. Engagement point 333 of the threaded screw303 engages the ground off end of factory pin 24. Using the leverage ofthe vehicle frame bracket 18, turning of the threaded screw 303 pushesthe upper factory pin 24 out of the opening defined in upper extensionmember 52 of factory hinge bracket 22 as well as out of upper opening 46defined in upper extension member 42 of the vehicle frame bracket 18.With such leverage, the pin is pushed out without bending or twistingthe vehicle frame bracket 18 due to the engagement or direct contact ofthe extension portion 306 with the upper extension member 42 of vehicleframe bracket 18.

After removal of the upper factory pin 24 and lower factory pin 26, oldworn out bushings can also be removed. As the repair of the factoryhinge 10 uses a substitute hinge pin and bracket apparatus 60, accordingto the present invention, the factory hinge bracket 22, upper and lowerfactory pins 24, 26, and factory bushings may be discarded, as they areno longer needed.

With the vehicle frame bracket 18 (e.g., the vehicle frame bracket 18typically being welded to the vehicle 9) being separated from thefactory hinge bracket 22 (e.g., factory pins and bushings removed), thesubstitute hinge bracket 62 of hinge pin and bracket apparatus 60 may beassembled with the vehicle frame bracket 18 using upper hinge pincomponents 64 and lower hinge pin components 66 of the hinge pin andbracket apparatus 60. Such assembly will be described with particularreference to FIGS. 3-4 and FIGS. 6-7. It will be apparent to one skilledin the art that one or more of the steps described in the repair of thehinge may be performed in a different order and/or may be optional.

First, the upper bushing 72 (e.g., a cylindrical element including a lipon one end and an opening defined therethrough) is positioned into upperopening 46 defined in upper extension member 42 of the vehicle framebracket 18 (e.g., the lip of the bushing rests on vehicle frame bracket18 keeping it from falling through the opening). Likewise, lower bushing82 (e.g., a cylindrical element including a lip on one end and anopening defined therethrough) is positioned into lower opening 48defined in lower extension member 44 of vehicle frame bracket 18 (e.g.,the lip of the bushing rests on vehicle frame bracket 18).

The substitute hinge bracket 62 of the hinge pin and bracket apparatus60 is placed into position between upper and lower extension members 42,44 of the vehicle frame bracket 18. The hinge bracket 62 is positionedsuch that the hinge bracket axis 93 and the factory frame bracket axis50 coincide which provides for alignment of upper and lower openings 46,48 defined in vehicle frame bracket 18 and upper and lower openings 97,98 defined in hinge bracket 62.

With the openings 46, 48 aligned with openings 97, 98, the upper hingepin 70 may be slid down through the upper bushing 72 which is alreadypositioned in the upper opening 46 defined in the upper extension member42 of the vehicle frame bracket 18. The locking surface 134 of the upperhinge pin 70 (e.g., the threaded locking surface 134) is then threadedinto the threaded locking surface 160 defining opening 97 of the hingebracket 62. The upper hinge pin 70 is tightened within the threadedlocking surface 160 of hinge bracket 62 until it is seated securely inthe substitute hinge bracket 62. A tool corresponding to the graspingsurface 140 of engagement element 138 may be used to tighten the pin 70until securely seated (e.g., a 15 millimeter open-ended wrench may beused to tighten the pin 70) in the substitute hinge bracket 62.

Thereafter, a washer 73 is slid over threaded end portion 132 of theupper hinge pin 70. Upper lock nut 74 is then threaded on the threadedend portion 132 and tightened (e.g., a 5/16^(th)-inch nut ishand-tightened). Preferably, air tools are not used so as to preventover-tightening.

In one embodiment, the dimensions of the pin and/or the bushing 72 maybe selected to reduce adverse effects from inadvertent over-tighteningof the nut 74. For example, in one embodiment, the smooth surface 136may have a sufficient length such that the shoulder 137 extends below alower surface of the upper extension member 42 when inserted into upperopening 46 thereof defined in the vehicle frame bracket 18. As a result,the nut 74 may be tightened against the shoulder 137 rather than thevehicle frame bracket 18. Over-torquing of the nut 74 does not,therefore, cause clamping of the hinge bracket 62 against the vehicleframe bracket 18.

Likewise, the length of upper bushing 72 (i.e., along hinge bracket axis93 when assembled) may also be sized such that the bushing extends belowthe lower surface of the upper extension member 42 of the vehicle framebracket 18. As such, tightening of the nut 74 is against an end of thebushing extending below the vehicle frame bracket 18 rather than thevehicle frame bracket 18 itself. Again, clamping of the hinge bracket 62against the vehicle frame bracket 18 is prevented.

In a similar manner to the assembly of upper hinge components 64, lowerhinge pin 80 is inserted through lower bushing 82 already positioned inlower opening 48 defined in extension member 44 of vehicle frame bracket18. The locking surface 156 (e.g., threaded surface 156) is threadedinto lower opening 98 defined by threaded locking surface 164. In amanner similar to the upper hinge pin 70, the pin is tightened securely(e.g., with use of grasping surfaces 160) until it seats completelywithin the substitute hinge bracket 62. Thereafter, lower washer 84 isslid over threaded end portion 152 and the nut 86 (e.g., lock nut) isthreaded onto the threaded end portion 152 and tightened.

During any tightening procedures, either one of the upper or lower hingepins 70, 80 may be grasped and held using the grasping surfaces 140, 160to hold the pins securely in place while tightening occurs. Further, thegrasping surfaces may be used to turn the pins 70, 80 into a seatedposition. Likewise, appropriate dimensions of the lower pin 80 and/orlower bushing 82 may be selected to reduce adverse effects frominadvertent over-tightening in the same manner as described above withreference to upper hinge pin 70. For example, the dimensions of lowerpin 80 may be such that shoulder 157 extends below a lower surface ofthe lower extension member 44 of the vehicle frame bracket 18, or thelength of lower bushing 82 may be sized such that a surface thereof isalso provided below the lower surface of the extension member 44 of thevehicle frame bracket 18 after insertion into lower opening 48 thereof.Again, as a result, over-torquing of the nut does not, therefore, causeclamping of the hinge bracket 62 against the vehicle frame bracket 18.

Various materials may be used in addition to those components describedherein to enhance functionality of the repaired hinge. For example,Locktite may be applied to the threaded openings 97, 98 of hinge bracket62, lubricant may be applied on the pins and bushing (e.g., whitelithium grease), or any other materials suitable for use with suchhinges may be employed.

With the hinge pin and bracket apparatus 60 installed and assembled withvehicle frame bracket 18, pin end portions 130, 150 of respective upperand lower pins 70, 80 are aligned along factory vehicle frame bracketaxis 50. Such pins are in substantially the same position as the upperfactory pin 24 and lower factory pin 26 prior to their removal.Likewise, preferably, hinge bracket 62 may be repositioned for couplingof factory door bracket 16 as the substitute hinge bracket 62 issubstantially the same as (at least in one embodiment) the configurationof the original factory hinge bracket 22, except for the addition oflocking surfaces 160, 164 defining openings 97, 98 of the hinge bracket62.

With the hinge pin and bracket apparatus 60 repositioned, reattachmentof the door 14 via the factory door bracket 16 may be accomplished.Again, one or more steps may be used to perform such reattachment of thedoor 14 as indicated in a factory manual including, for example,coupling of door bracket 16 and hinge bracket 62 via a bolt through boltslot 91 of hinge bracket 62 and factory adjustment slot 43 of factorydoor bracket 16. Suitable adjustment may be made to the door 14 afterthe upper opening 34 of door bracket 16 and the lower opening 36 of doorbracket 16 are positioned on the substitute upper and lower hinge pins70, 80.

One or more of the following various features and benefits may beaccomplished using one or more components of the hinge pin and bracketapparatus 60, according to the present invention. For example, the pinsare preferably hardened or otherwise treated, to have a hardness that isgreater than the hardness (HRB) of the original factory pins. Forexample, preferably, the hardness is greater than about 80 Rockwell Bhardness (HRB). With use of such materials, or treated materials, thepotential for breakage of such pins is substantially reduced.

In another embodiment, the pins are manufactured from 1045 high carbonsteel (or any steel having a strength or a hardness greater than 1018steel). This is unlike the factory pins which are manufactured from alower carbon 1018 steel (e.g., generally a softer material is requiredso that the ends of the factory pins can be peened). The higher strengthmaterial may be necessary to pull the pins into place as the nuts arebeing tightened, such as, for example, in the hinge pin repairembodiment shown in FIGS. 14-16. Yet further, in one embodiment,stainless steel may be used for providing one or more parts describedherein, such as the hinge bracket and/or the pins.

Further, in one or more embodiments, the pins are machined with flatsurfaces (e.g., grasp surfaces 140, 160) to allow the installer totighten the pins with a particular tool (e.g., a 15-millimeteropen-ended wrench). Yet further, such pins may be coated to preventrusting (e.g., yellow dichromate coated).

With use of the locking surfaces of the pins and their correspondinglocking surfaces of the hinge bracket 62, the design allows the hingeassembly to be disassembled for future repairs, if necessary.

FIGS. 11A-11C show perspective views of an alternate hinge pin andbracket apparatus. FIG. 11A shows a perspective view of an alternateembodiment of an upper hinge pin 170, FIG. 11B shows a perspective viewof an alternate embodiment of a lower hinge pin 180, and FIG. 11C showsa perspective view of an alternate embodiment of a hinge bracket 190 tobe used with upper and lower hinge pins 170, 180.

The upper hinge pin 170, the lower hinge pin 180, and the correspondinghinge bracket 190 are substantially similar to the same componentsdescribed with reference to FIGS. 3-10. However, a different type oflocking surface is utilized in such components. One skilled in the artwill recognize that any number of different types of locking surfacesbetween the upper and lower hinge pins and the hinge bracket may be usedas long as the pins, when seated in the corresponding hinge bracket, donot move therein (e.g., when seated, the pins are not allowed to rotatewith respect to the hinge bracket to which they are coupled and locked).

As shown in FIGS. 11A, the upper hinge pin 170 includes an elongatedbody portion 271 extending from a threaded end portion 232 to a pin endportion 230 along axis 229. A locking surface 234 lies along the axis229 between the threaded end portion 232 and the pin end portion 230.The locking surface 234 comprises flat surfaces 233 that correspond tosimilar flat surfaces 289 of opening 289 defined in bracket 190 andprovide for a locking functionality between the upper pin 170 and theupper opening 289 of hinge bracket 190.

Also lying along axis 229 between threaded end portion 232 and pin endportion 230 is smooth surface 236 that generally corresponds to anopening of a bushing through which the upper hinge pin 170 is to beinserted when assembled. As shown in FIG. 11A, the smooth surface 236lies between the locking surface 234 and pin end portion 230.

The upper hinge pin 170 further includes an engagement element 238 lyingalong axis 229 and which extends further from axis 229 than otherportions of the elongated pin body portion 271. As such, a lower surface241 is provided for contact with other components so as to maintain pinend portion 230 available to receive a factory door bracket, such asfactory door bracket 16 shown and described with reference to FIGS.1A-1B. The pin end portion 230 further includes a tapered end 231 forease in receiving the factory door bracket 16 as the opening 34 of thefactory door bracket 16 is placed over the tapered end 231. Theengagement element 238 further includes one or more grasp surfaces 240in a manner similar to those already described herein.

As shown in FIGS. 11B, the lower hinge pin 180 includes an elongatedbody portion 253 extending from a threaded end portion 252 to a pin endportion 250 along axis 249. A locking surface 256 lies along the axis249 between the threaded end portion 252 and the pin end portion 250.The locking surface 256 comprises flat surfaces 257 that correspond tosimilar flat surfaces 287 of opening 298 defined in bracket 190 andprovide for a locking functionality between the lower pin 180 and theupper opening 298 of hinge bracket 190.

Also lying along axis 249 between threaded end portion 252 and pin endportion 250 is smooth surface 254 that generally corresponds to anopening of a bushing through which the lower hinge pin 180 is to beinserted when assembled. As shown in FIG. 11A, the smooth surface 254lies between the locking surface 256 and threaded end portion 252.

The lower hinge pin 180 further includes an engagement element 258 lyingalong axis 249 and which extends further from axis 249 than otherportions of the elongated pin body portion 253. As such, a lower surface259 is provided for contact with other components so as to maintain pinend portion 250 available to receive a factory door bracket, such asfactory door bracket 16 shown and described with reference to FIGS.1A-1B. The pin end portion 250 further includes a tapered end 251 forease in receiving the factory door bracket 16 as the opening 36 of thefactory door bracket 16 is placed over the tapered end 251. Theengagement element 258 further includes one or more grasp surfaces 260in a manner similar to those already described herein.

The hinge bracket 190 is, at least in one embodiment, of the same shapeand size as factory hinge bracket 22 for which it is to replace.However, instead of having openings like those of the factory hingebracket 22 through which factory pins are inserted, the hinge bracket 62to be substituted for the factory hinge bracket 22 includes openings297, 298 defined therein by locking surfaces 289, 287, respectively,which correspond to locking surfaces 233, 257 of upper hinge pin 170 andlower hinge pin 180, respectively.

As shown in FIG. 11C, the hinge bracket 190 includes a bracket body 290with two spaced apart extension members 292, 294 extending therefrom. Atleast in one embodiment, such extension members 292, 294 each have atleast a portion which are substantially parallel to one another. Anopening 297 is defined in the upper extension member 292 and an opening298 is defined in the lower extension member 294. Such openings 297, 298lie substantially orthogonal to hinge bracket axis 293. Generally, thedistance between upper extension member 292 and lower extension member294 is such that the hinge bracket 190 may be inserted between extensionmembers 42, 44 of vehicle frame bracket 18, such as described withreference to FIGS. 1-2. As shown in FIG. 11C, the locking surfaces 289,287 (e.g., flat surfaces) correspond to the locking surface regions 233,257 of upper hinge pin 170 and lower hinge pin 180, respectively.

The substitute hinge bracket 190 (e.g., substitute for a factory hingebracket) also includes bolt opening 291 in substantially the samelocation as the factory hinge bracket (e.g., hinge bracket 22) which itis to replace. As such, hinge bracket 190, at least in one embodiment,includes substantially all the features present in the factory hingewhich it is to replace.

As the method of repair using the alternate hinge pin and bracketapparatus (i.e., including upper hinge pin 170, lower hinge pin 180, andhinge bracket 190) would be readily apparent from the descriptionprovided herein with respect to the repair of hinge 10 using hinge pinand bracket apparatus 60, for simplicity purposes, such a repair methodshall not be provided in any further detail.

One or more components as described herein may be provided as a repairkit for the repair of a factory hinge such as shown and described withreference to FIGS. 14-16. For example, the hinge pin apparatus 500, asshown in FIG. 14, includes components (e.g., upper hinge pin components502 and lower hinge pin components 504) for repair of a passenger's sidedoor hinge which includes factory vehicle frame bracket 19 (see alsoFIG. 5) and factory vehicle hinge bracket 17. One skilled in the artwill recognize that one or more of such kit elements may be optional.For example, washers (e.g., lock washers) shown as part of lower hingepin components 504 may optionally be used according to the presentinvention. Further, a kit may be provided with any combination of therepair components described herein.

The hinge pin apparatus 500 is used to repair hinges without use of asubstitute hinge bracket as described with reference to FIGS. 4-11.Rather, different types of pins 510 and 520 are used with the factoryhinge bracket 17 to make the repair as will be apparent from thedescription herein.

Upper hinge pin components 502, at least in one embodiment, includeupper pin 510, upper bushing 512, and upper lock nut 514. Likewise,lower hinge pin components 504 include lower pin 520, lower bushing 522,lower washer 524, and lower lock nut 526. Such components 502, 504 areshown unassembled in the exploded view of FIG. 14 along with factoryvehicle passenger side frame bracket 19 and factory vehicle passengerside hinge bracket 17. Such components when assembled are much like theconfigurations shown in FIGS. 4 and 7 but with the alternate components(e.g., the factory hinge bracket and the pins 510, 520).

The factory frame bracket 19 is generally attached to the vehicle frame(e.g., welded) like that of bracket 18 as described herein and thefactory hinge bracket 17 is coupled to the factory vehicle frame bracket19 using an upper factory pin and a lower factory pin (not shown).

The factory vehicle frame bracket 19, as shown in FIG. 14, generallyincludes a body portion 740 for attachment to the vehicle frame alongwith spaced apart extension members 742, 744 extending from the bodyportion 740. An upper opening 746 is defined in the upper extensionmember 742 and a lower opening 748 is generally defined in lowerextension member 744. The upper opening 746 and lower opening 748 aretypically orthogonal to a factory frame bracket axis 701 along whichsuch openings 746, 748 lie.

The factory hinge bracket 17 includes a body portion 728 having twospaced apart extension members 730, 732 extending therefrom. Theextension members 730, 732 are generally configured such that thefactory hinge bracket 17 fits within a space defined by the extensionmembers 742, 744 of factory vehicle frame bracket 19. The factory hingebracket 17 further includes an opening 734 defined in extension member730 and an opening 736 defined in extension member 732. When the factoryhinge bracket 17 and the vehicle frame bracket 19 are assembled, theopenings 734, 736 defined in each of extensions members 730, 732 and theopenings 746, 748 defined in extension members 742, 744 of the vehicleframe bracket 19 are generally aligned along axis 701 of the vehicleframe bracket 19 and lie orthogonal thereto.

FIGS. 15A-15B show a side view and a top view of one embodiment of anupper hinge pin 510 shown generally in FIG. 14 according to the presentinvention. The upper hinge pin 510 includes an elongated body portion539 extending from a threaded end portion 538 to a pin end portion 533along axis 531.

An interference portion 536 lies along the axis 531 between the threadedend portion 538 and the pin end portion 533. The interference portion536, as shall be described further herein, is shown as a knurl in FIGS.15A-15B. However, according to the present invention, any interferenceportion that provides for an interference fit with one or more surfacesthat define the upper opening 730 of the hinge bracket 17 may be used.For example, the knurl shown in FIGS. 15A-15B includes ridges (e.g.,peaks and valleys that lie in the direction of axis 531 and at a radialdistance therefrom) that provide for contact pressure between the knurland the surface(s) defining the opening 730. As used herein, aninterference fit refers to any fit where contact pressure is presentbetween surfaces, or portions of surfaces, of two parts (e.g., betweenthe knurl 536 and the surface defining the opening 730).

Also lying along axis 531 between threaded end portion 538 and pin endportion 533 is smooth surface 537. As will be recognized upon reading ofthe description relating to the repair of the hinge, smooth surface 537generally corresponds to an opening of bushing 512 through which theupper hinge pin 510 is inserted (e.g., the smooth surface 537 isgenerally adjacent an inner surface of bushing 512 when assembled).

As shown in FIG. 15A, the smooth surface 537 lies between theinterference portion 536 and pin end portion 533. At the interfacebetween smooth surface 537 and interference portion 536 is a shoulder534. Although shown as a very small shoulder at the interface, one willrecognize that by changing the diameter of the smooth surface 537 or theinterference portion 536, that such shoulder 534 may be enlarged andprovide even a greater contact area for use in coupling with othercomponents of the hinge. For example, this shoulder 534 may contactextension member 730 of hinge bracket 17 when the hinge is assembled.The interference portion 536 extends to the shoulder 534 such thatsubstantially (i.e., in this instance substantially refers to nearly100%) the entire inner surface defining the opening 734 of the hingebracket 17 is in contact with the interference portion 536 when theinterference portion 536 of the pin 510 is positioned in the opening 734of the hinge bracket 17 upon assembly. In other words, in oneembodiment, the knurl fills the entire opening 734.

The upper hinge pin 510 further includes an engagement element 532 lyingalong axis 531 and which extends further radially from axis 531 thanother portions of the elongated pin body portion 539. As such, a lowersurface 581 is provided for contact with other components so as tomaintain pin end portion 533 available to receive a factory doorbracket, such as a factory door bracket like that of door bracket 16shown and described with reference to FIGS. 1A-1B. The pin end portion533 further includes a tapered end 551 for ease in receiving the factorydoor bracket as the opening of a factory door bracket is placed over thetapered end 551.

The engagement element 532 further includes one or more grasp surfaces558. The one or more grasp surfaces 558 are configured in acorresponding manner to one or more tools capable of grasping andholding (and/or turning) the upper pin 510 as the hinge pin apparatus500 is being assembled in relation to factory hinge bracket 17 and/orvehicle frame bracket 19, as shall be further described herein. Oneskilled in the art will recognize that such grasping surfaces 558 may beflat surfaces that can be grasped (i.e., to hold the pin 510) by awrench, a socket, or any other tool capable of grasping and holding(and/or turning) the upper hinge pin 510 during assembly. For example,the grasp surfaces may include six flat surfaces in the form ofsubstantially a hexagon such that a socket wrench may be used to holdthe upper hinge pin 510.

FIGS. 16A-16B show a side view and a top view of one embodiment of alower hinge pin 520 shown generally in FIG. 14 according to the presentinvention. The lower hinge pin 520 includes an elongated body portion549 extending from a threaded end portion 548 to a pin end portion 543along axis 541.

An interference portion 546 lies along the axis 541 between the threadedend portion 548 and the pin end portion 543. The interference portion546, as shall be described further herein, is shown as a knurl in FIGS.16A-16B. However, as described above with respect to the upper hinge pin510, any interference portion that provides for an interference fit withone or more surfaces defining the opening 736 in extension member 732 ofhinge bracket 17 may be used.

Also lying along axis 541 between threaded end portion 548 and pin endportion 543 is smooth surface 547. As will be recognized upon reading ofthe description relating to the hinge repair, smooth surface 547generally corresponds to an opening of bushing 522 through which thelower hinge pin 520 is inserted (e.g., the smooth surface 547 isgenerally adjacent an inner surface of bushing 522 when assembled). Asshown in FIG. 16A, the smooth surface 547 lies between the threaded endportion 548 and interference portion 546.

The lower hinge pin 520 further includes an engagement element 542 lyingalong axis 541 and which extends further from axis 541 than otherportions of the elongated pin body portion 549. As such, a lower surface544 is provided for contact with other components so as to maintain pinend portion 543 available to receive a factory door bracket, similar tothe factory door bracket 16 shown and described with reference to FIGS.1A-1B. The pin end portion 543 further includes a tapered end 561 forease in receiving the factory door bracket as an opening of the factorydoor bracket is placed over the tapered end 561.

The lower surface 544 of the engagement element 542 will contact anupper surface of extension member 732 of hinge bracket 17 when the hingeis assembled. The interference portion 546 extends to the lower surface544 such that substantially (i.e., in this instance substantially refersto nearly 100%) the entire inner surface defining the opening 736 of thehinge bracket 17 is in contact with the interference portion 546 whenthe interference portion 546 of the pin 520 is positioned in the opening736 of the hinge bracket 17 upon assembly. In other words, in oneembodiment, the knurl fills the entire opening 736.

The engagement element 542 further includes one or more grasp surfaces568. The one or more grasp surfaces 568 are configured in acorresponding manner to one or more tools capable of grasping andholding (and/or turning) the lower pin 520 as the hinge is beingrepaired. One skilled in the art will recognize that such graspingsurfaces 568 may be the same or different than those described withreference to upper hinge pin 510.

With provision of hinge pin apparatus 500, a method of repairing afactory hinge shall be described with reference to FIGS. 14-16. To beginthe repair process, the passenger's side door is removed from thevehicle. Generally, removal of door is described in a factory providedmanual and may include one or more various steps. Removal of passenger'sside door would include at least removal of a factory bolt that couplesthe factory hinge bracket 17 to a factory door bracket attached to thedoor. Likewise, the door must then be lifted off of an upper factory pinand lower factory pin. The peened ends of upper factory pin and lowerfactory pin, respectively, must then be removed. For example, any sortof removal method may be used, such as, for example, grinding off of thepeened ends.

Thereafter, the upper factory pin and the lower factory pin are removed.For example, such factory pins may be removed using a hole punch.However, preferably, any method suitable to remove the upper and lowerfactory pins without bending the vehicle frame bracket 19 and factoryhinge bracket 17 can be utilized. In one embodiment, the punch-out blocktool 302, as shown in FIGS. 12-13, may be used to remove the upper andlower factory pins.

After removal of the upper factory pin and lower factory pin, old wornout bushings can also be removed. However, in this embodiment, since therepair of the factory hinge uses the factory hinge bracket 17, it isretained for later assembly. However, the upper and lower factory pins,and factory bushings may be discarded, as they are no longer needed.

With the vehicle frame bracket 19 being separated from the factory hingebracket 17 (e.g., factory pins and bushings removed), the hinge pinapparatus 500 may be assembled with the vehicle frame bracket 19 andfactory hinge bracket 17 using upper hinge pin components 502 and lowerhinge pin components 504. It will be apparent to one skilled in the artthat one or more of the steps described in the repair of the hinge maybe performed in a different order and/or may be optional.

First, the upper bushing 512 (e.g., a cylindrical element including alip on one end and an opening defined therethrough) is positioned intoupper opening 746 defined in upper extension member 742 of the vehicleframe bracket 19 (e.g., the lip of the bushing rests on vehicle framebracket 19 keeping it from falling through the opening). Likewise, lowerbushing 522 (e.g., a cylindrical element including a lip on one end andan opening defined therethrough) is positioned into lower opening 748defined in lower extension member 744 of vehicle frame bracket 19 (e.g.,the lip of the bushing rests on vehicle frame bracket 19).

The factory hinge bracket 17 is placed into position between upper andlower extension members 742, 744 of the vehicle frame bracket 19. Thefactory hinge bracket 17 is positioned so as to provide for alignment ofupper and lower openings 746, 748 defined in vehicle frame bracket 19and upper and lower openings 734, 736 defined in factory hinge bracket17.

With the openings 746, 748 aligned with openings 734, 736, the upperhinge pin 510 may be slid down through the upper bushing 512 which isalready positioned in the upper opening 746 defined in the upperextension member 742 of the vehicle frame bracket 19. Upper lock nut 514is then threaded on the threaded end portion 538 and tightened (e.g., byhand).

In a similar manner to the assembly of upper hinge components 502, lowerbinge pin 520 is inserted through lower bushing 522 already positionedin lower opening 748 defined in extension member 744 of vehicle framebracket 19. Thereafter, lower washer 524 is slid over threaded endportion 548 and the nut 526 (e.g., nylon lined lock nut) is threadedonto the threaded end portion 548 and tightened.

The nuts 514, 526 are then tightened until the interference portions536, 546 are seated properly in the openings 734, 736 of factory hingebracket 17. During any tightening procedures, either one of the upper orlower hinge pins 510, 520 may be grasped and held using the graspingsurfaces 558, 568 to hold the pins securely in place while tighteningoccurs. Further, the grasping surfaces may be used to turn the pins 510,520 into a seated position.

With the hinge pin apparatus 500 installed and assembled with vehicleframe bracket 19 and factory hinge bracket 17, pin end portions 533, 543of respective upper and lower pins 510, 520 are aligned along thefactory vehicle frame bracket axis 701. Such pins are in substantiallythe same position as the upper factory pin and lower factory pin priorto their removal. Likewise, preferably, factory hinge bracket 17 may berepositioned for coupling of a factory door bracket thereto. Thereafter,reattachment of the passenger side door via the factory door bracket maybe accomplished.

All references cited herein are incorporated in their entirety as ifeach were incorporated separately. This invention has been describedwith reference to illustrative embodiments and is not meant to beconstrued in a limiting sense. Various modifications of the illustrativeembodiments, as well as additional embodiments of the invention, will beapparent to persons skilled in the art upon reference to thisdescription.

1-28. (canceled)
 29. A punch tool apparatus for use in repairing a doorhinge, wherein the door hinge comprises at least a vehicle frame bracketattached to a portion of a vehicle frame and a hinge bracket, whereinthe vehicle frame bracket comprises a first and second opening alignedalong and lying orthogonal to a frame bracket axis, wherein the hingebracket comprises a first and second opening aligned along and lyingorthogonal to the frame bracket axis, wherein the vehicle frame bracketand the hinge bracket are coupled using a first pin positioned in thefirst opening of the vehicle frame bracket and the first opening of thehinge bracket and using a second pin positioned in the second opening ofthe vehicle frame bracket and the second opening of the hinge bracket,wherein the punch tool apparatus comprises: a body portion; and firstand second spaced apart portions extending from the body portion todefine a bracket receiving region therebetween configured to receive aportion of the vehicle frame bracket and the hinge bracket when the toolis used to remove one of the first and second pins, wherein one of thefirst and second spaced apart portions defines a pin receiving regionconfigured to receive one of the first and second pins when the tool isused to remove the pin and the other of the first and second spacedapart portions defines a threaded opening configured to receive athreaded punch operable to engage the pin when the tool is being used toremove the pin.
 30. The punch tool apparatus of claim 29, wherein thebody portion comprises an elongate member extending from a first endregion to a second end region, and further wherein the first and secondspaced apart portions extend orthogonal to the elongate member from thefirst end region and second end region, respectively.
 31. The punch toolapparatus of claim 29, wherein the threaded punch terminates in anengagement point to engage an end of the pin to be removed.
 32. Thepunch tool apparatus of claim 31, wherein the threaded punch comprises athreaded punch screw.
 33. A kit for use in repairing a door hinge,wherein the door hinge comprises at least a vehicle frame bracketattached to a portion of a vehicle frame and a hinge bracket, whereinthe vehicle frame bracket comprises a first and second opening alignedalong and lying orthogonal to a frame bracket axis, wherein the hingebracket comprises a first and second opening aligned along and lyingorthogonal to the frame bracket axis, wherein the vehicle frame bracketand the hinge bracket are coupled using a first pin positioned in thefirst opening of the vehicle frame bracket and the first opening of thehinge bracket and using a second pin positioned in the second opening ofthe vehicle frame bracket and the second opening of the hinge bracket,wherein the kit comprises: a punch tool apparatus comprising: a bodyportion; and first and second spaced apart portions extending from thebody portion to define a bracket receiving region therebetweenconfigured to receive a portion of the vehicle frame bracket and thehinge bracket when the tool is used to remove one of the first andsecond pins, wherein one of the first and second spaced apart portionsdefines a pin receiving region configured to receive one of the firstand second pins when the tool is used to remove the pin and the other ofthe first and second spaced apart portions defines a threaded openingconfigured to receive a threaded punch operable to engage the pin whenthe tool is being used to remove the pin; and at least one substitutepin for use in replacing one of the first and second pins.
 34. The kitof claim 33, wherein the kit further comprises at least one substitutebracket for use in replacing the hinge bracket.
 35. The kit of claim 34,wherein the at least one substitute pin comprises a locking portion,wherein the at least one substitute bracket comprises at least a firstopening corresponding to the first opening of the vehicle frame bracketand a second opening corresponding to the second opening of the vehicleframe bracket, wherein at least one of the first and second openings ofthe substitute bracket is defined by a locking surface configured as afunction of the locking portion of the at least one substitute pin. 36.The kit of claim 35, wherein the locking portion of the at least onesubstitute pin comprises a threaded region, and further wherein at leasta portion of the locking surface is threaded for receiving the threadedregion of the at least one substitute pin.
 37. The kit of claim 33,wherein the body portion of the punch tool apparatus comprises anelongate member extending from a first end region to a second endregion, and further wherein the first and second spaced apart portionsextend orthogonal to the elongate member from the first end region andsecond end region, respectively.
 38. The kit of claim 33, wherein thethreaded punch terminates in an engagement point to engage an end of thepin to be removed.
 39. The kit of claim 38, wherein the threaded punchcomprises a threaded punch screw.